Mk1 16v Project

I've been pretty bored this weekend.. So after i got sick of scrambling my Rubiks cube and solving it and then seeing what pattern i could create umpteen times....

http://i280.photobucket.com/albums/k...1020081651.jpg

I decided it was time to go machine something.. Anything! haha.

The best choice i came up with was lightening my intermediate shaft.

I chucked it in the lathe and went to town on it..

The casting, although quite good, with virtually no mismatch was eccentric but about 1.5mm! Bloody terrible.

http://i280.photobucket.com/albums/k...1020081652.jpg

http://i280.photobucket.com/albums/k...1020081653.jpg

The shaft, between the 2 journals basically tapers from one end to the other. Luckily the smaller end is pretty close to spot on concentric, and then it obviously gets worse as if moves along to the other end.

What i have done is turned it down to 18.0mm from one end to the other, with 9mm radii in the corners to ensure there is no weak point. 18mm was just enough to clean up the smaller end.

http://i280.photobucket.com/albums/k...1020081654.jpg

http://i280.photobucket.com/albums/k...1020081655.jpg

http://i280.photobucket.com/albums/k...1020081656.jpg

http://i280.photobucket.com/albums/k...1020081657.jpg

Obviously, the shaft would still not be perfectly balanced, but it would be more than close enough. Because it runs at half speed, at maximum engine speed, which in my case will hopefully be about 9000rpm or a little less, the intermediate shaft will be doings no more than 4500rpm ever. Also, there is much less rotating mass aswell as a very small diameter. So therefore, balancing is much less critical.

If anyone else is interested, i can provide these types of services for them, too. (Hows that for blowing my own trumpet.. :biggrin: )

Quote:

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Originally Posted by Preen59

http://www.vwwatercooled.com.au/forums/

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I reckon you just pulled the sticker's off & swapped them around! :nana:

Top work as alway's Preeny.

Quote:

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Originally Posted by golfworx

I reckon you just pulled the sticker's off & swapped them around! :nana:

Top work as alway's Preeny.

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Hahaha I'll bring it to melbourne and teach you how if you like. Kinda ruins the mystery when you know how though.

Thanks Tim.

Oh, and no wise cracks about the Aviators? that surprises me.. :D

Quote:

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Originally Posted by Preen59

...Oh, and no wise cracks about the Aviators? that surprises me.. :D

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Actually, when I first saw them, I thought "oh no, Preeny's been milling with the avaitors on again!" and got an image of you with ya tounge out milling away at the shaft with ya shades on!

hahaha.

You make me laugh.

EDIT: I see you've also put the rear visor on too! nice one!

Jarred, that aint no mill!!!! thats a lathe ;)


however as a fellow aviator wearer i couldnt bare to make a wise crack about them hahah :D

Quote:

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Originally Posted by Jarred

I see you've also put the rear visor on too! nice one!

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Haha its held on by the rear wiper at the moment!!

Quote:

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Originally Posted by GoLfMan

Jarred, that aint no mill!!!! thats a lathe ;)


however as a fellow aviator wearer i couldnt bare to make a wise crack about them hahah :D

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Hahaha nice. I was going to mention that.

Ok enough clagging up the thread! :)

When i was back at my previous work i checked the balance of two 8v standard intermediate shafts on a dynamic balancer and just for interest sake they were both under 2 grams of balance at 500rpm. They were just like preeny said....

The casting, although quite good, with virtually no mismatch was eccentric but about 1.5mm! Bloody terrible.

But this was done by the factory to offset the cam lobe for the mechanical fuel pump...

Good work Preen once again! Im currently hunting for a techtonics intermediate shaft pulley if your keen for one that will match your cam gear let me know bro.

Quote:

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Originally Posted by twin eng, twin turbs

this was done by the factory to offset the cam lobe for the mechanical fuel pump...

Good work Preen once again! Im currently hunting for a techtonics intermediate shaft pulley if your keen for one that will match your cam gear let me know bro.

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Ahh makes sense.

Yeah if you can find one snap one up for me! My TT cam gear hasn't turned up yet.. :brutal: Not happy.

Quote:

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Originally Posted by Preen59

Ahh makes sense.

Yeah if you can find one snap one up for me! My TT cam gear hasn't turned up yet.. :brutal: Not happy.

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My cam gear came in under 2 weeks after i paid, it will turn up..... eventually i hope for your sake

Mmm, nice lathe! Better than the old beast at my work that just ovalised my top mounts!!!!